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Lean manufacturing and happy employees.

Graham Immerman
April 30, 2018

Lean manufacturing techniques can bring more than just a better OEE. Industry Week said, "Any operator or maintenance person I’ve ever talked to has a much better day when the machine is running properly than when it is not, so it’s usually easy to get their support." Our real time analytics can help resolve those problems quickly to get everyone working efficiently and happily. "A lost machine hour on a constraint work center is an immediate hit to operating margin and maybe to your best customer’s order delivery promise."

Ask the Expert: Lean Leadership -- Can We Talk About OEE?Source: http://www.industryweek.com

Utilization (hours of actual machine uptime ÷ scheduled hours): Typically, the biggest reductions to utilization are due to set-ups and maintenance downtime.  To reduce the impact of set-up times on machine throughput, you must measure and report the time spent on set-ups as a discrete measure for each machine.  You can do the same for time spent on PMs.  Data should be collected so that accounting can calculate the variance, +/- the standard.  Importantly, from a capacity standpoint it doesn’t matter on a constraint—it’s still lost production time.  Focus on why machines are down regardless of whether it’s planned or unplanned.  That will identify where the biggest opportunities lie so you can do a kaizen blitz on the right machines.  Always work on the constraint work centers first!  Let’s assume the utilization for the machine is 75% in a 120-hour week, i.e., 40 hours times 3 shifts x .75 = 90.  That means the machine is available for production 90 hours a week.  Lots of opportunity to improve throughput. Read More

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